Operating Instructions Manual No. M09-1200-F1016

BROOKFIELD POWDER FLOW TESTER

Operating Instructions

Manual No. M09-1200-F1016

Instrumentation & Specialty Controls Division

11 Commerce Boulevard, Middleboro, MA 02302 USATel: 508-946-6200 or 800-628-8139 (USA excluding MA)Fax: 508-946-6262 Internet http://www.brookfieldengineering.com

Table of ContentsI. INTRODUCTION ......................................................................................................................................5

I.1 Components ......................................................................................................................................... 6I.2 Utilities .................................................................................................................................................................7I.3 Specifications .......................................................................................................................................................7I.4 Dimensions ..........................................................................................................................................................9I.5 Safety Symbols and Precautions ........................................................................................................................10I.6 Back Panel ......................................................................................................................................................... 11I.7 Key Functions ....................................................................................................................................................12I.8 Test Stop - Reset ................................................................................................................................................12I.9 Installation ..........................................................................................................................................................13I.10 Cleaning .............................................................................................................................................................14

II. QUICK START PROCEDURE ................................................................................................................. 15 III. SAMPLE PREPARATION AND HANDLING .......................................................................................... 19

III.1 Sample Issues ...................................................................................................................................................19III.2 Sample Trough .................................................................................................................................................20III.3 Lid Selection ....................................................................................................................................................21III.4 Outer Catch Tray ..............................................................................................................................................22III.5 Inner Catch Tray with Shaping Blade ..............................................................................................................22III.6 Loading the Trough with Sample .....................................................................................................................23III.7 Placement of the Trough and Lid on the Instrument ........................................................................................23III.8 Removal of Trough and Lid from Instrument ..................................................................................................24III.9 Clean-up ...........................................................................................................................................................24

IV. POWDER FLOW PRO SOFTWARE ........................................................................................................ 25IV.1 Main Screen and Setup Tab ..............................................................................................................................25IV.2 Sample Information ..........................................................................................................................................26IV.3 Standard Test Method .......................................................................................................................................27IV.4 Custom Test Method ........................................................................................................................................28IV.5 Test Execution ..................................................................................................................................................29IV.6 How to Stop the Test ........................................................................................................................................34IV.7 Analysis Section ...............................................................................................................................................35

IV.7.1 How to Save Data ..............................................................................................................................35IV.7.2 Choices for Data Display ..................................................................................................................35IV.7.3 How to Create a Data Report ............................................................................................................44IV.7.4 How to Compare Data .......................................................................................................................45

IV.8 Statistics Page...................................................................................................................................................47IV.9 Custom Page.....................................................................................................................................................49IV.10 Importing and Exporting Data .........................................................................................................................50IV.11 Help Files .........................................................................................................................................................50

Appendix A: Overview of Powder Flow Properties ........................................................................................ 51Appendix B:BCR-LimestoneTestProcedureforCalibrationCheckonBrookfieldPowderFlowTester ..... 59Appendix C: Glossary ...................................................................................................................................... 61Appendix D: PFT Packing to Ship for Repair and Service .............................................................................. 64Appendix E: Warranty Repair and Service ...................................................................................................... 73

AMETEK Brookfield Manual No. M09-1200-F1016

I. INTRODUCTION

Thereisaneedthroughoutindustrytocharacterizepowderflowpropertiesandflowbehavior.TheBrookfieldPowderFlowTester(PFT)isaprecisioninstrumentofrobustdesignthatsatisfiesthisneedandcanbeusedtomeasure,displayandprintoutflowresultsatspecifiedcompactionloads. Potential users include R&D Departments, QC laboratories, Incoming Inspection for raw materials, and government/university organizations.

The principal of operation of the PFT is to drive a compression lid vertically downward into a powdersamplecontainedinanannularshearcell.Thepowdersamplehasadefinedvolumeand the weight of the sample is measured before the start of the test. A calibrated beam load cell is used to control the compaction stress applied to the powder. The annular shear cell is thenrotatedatadefinedspeedandthetorqueresistanceofthepowderintheshearcellmovingagainstthepowderinthestationarylidismeasuredbyacalibratedreactiontorquesensor.Thegeometries of the lid, shear cell, rotational speed of the cell, and the compressive loads applied tothepowderallcontributetothecalculationswhichdeterminethe“flowability”ofthepowder.

The intended uses for the PFT include: • Pass/failteststocertifymaterialqualitypriortoshipment• Providingmeaningfulnumbersthatguidehowpowderwillflowinsilos,hoppers,feeders,

fillingmachinesandsimilarequipment• Benchmarkingfordailyproductionlotsorforcomparingflowbehaviorofnew

formulations against existing product• Creating databases for choice of production lines, sourcing, formulation and second source

suppliers• Producingquantitativeresultsthatcanbeusedfordesignofprocessingplantsand

equipment

Thereareseveralpowderflowpropertieswhich thePFTmeasures tocategorizeflowability.Note that these properties, which may vary with changes in temperature and humidity, include:• Unconfinedfailurestrength• Major Principal Consolidating Stress• Time Consolidation• Angle of internal friction• Angle of wall friction• Cohesive strength• Bulk density

Themostrecognizedindicationofpowderflowabilityistheunconfinedfailurestrengthwhenviewedasafunctionoftheconsolidatingstress,knownastheflowfunction.Wallfriction,internalfriction,andbulkdensityarealsocommonlyused to relatemeasurements toflowbehavior.Appendix A provides a more detailed explanation of these properties and how they are measured.


I.1 Components

DESCRIPTION PART NUMBERThe following items are included with your instrument: Powder Flow TesterPowder Flow Tester 115VAC or PFT3115 Powder Flow Tester 230VAC PFT3230Powder Flow Pro Software with USB cable PFT-609Power Cord 115 Volt or DVP-65Power Cord 230 Volt DVP-66 Standard Accessory Kit PFT-610 Includes the following items:

• SampleTroughAluminum(230cc,6-in.dia.) PFT-400• VaneLid304S/S(34cc,6-in.dia.) PFT-500 • WallLid304S/S,2Bfinish(6-in.dia.) PFT-507 • Catch Trays & Shaping Blade PFT-600• Powder Scoop PFT-611• Cleaning Brush PFT-612 • 3/8”Wrench[forlevelingtheinstrument] CP-23• Shipping Foam PFT-101• Operator Manual M09-1200

Optional Items for Standard Accessory KitWall Lid, Tivar 88, 6-in. dia. PFT-512Wall Lid, Mild Steel, 6-in. dia. PFT-513Portable Carrying Case RK-PFTCCKIT

Optional Small Volume Shear Cell Kit Includes the following items: PFT-620

• SmallTrough(38cc,5-in.dia.) PFT-405• SmallVaneLid,304S/S(5cc,5-in.dia.) PFT-515• SmallWallLid,304S/S,2BFinish(5-in.dia.) PFT-516• Catch Trays & Shaping Blade PFT-618• Powder Scoop PFT-611• Cleaning Brush PFT-612• Wrench[forlevelingtheinstrument] CP-23• Shipping Foam PFT-106

Optional Accessory Items for Small Volume KitWall Lid, Tivar 88, 5-in. dia. PFT-520Wall Lid, Mild Steel, 5-in. dia. PFT-522

Optional Accessory items that can be ordered for use with the Powder Flow Testerinclude the following: Humidity Sensor with interface cable PFT-607Y RTD Temperature Sensor with interface cable DVP-94YSampleTroughAluminum(230cc,6-in.dia.) PFT-400SampleTroughAluminum(230cc,5-in.dia.) PFT-405


PerforatedScreen(230cc,6-in.dia.) PFT-440 PerforatedScreen(230cc,5-in.dia.) PFT-442InnerCatchTraywithShapingBlade(230cc,6-in.dia.) PFT-6Y InnerCatchTraywithShapingBlade(230cc,5-in.dia.) PFT-5YOuterCatchTray(230cc,6-in.dia.) PFT-8 OuterCatchTray(230cc,5-in.dia.) PFT-7

Sieve KitsPFT Sieve Kit for Standard Cell PFT-626

• Adapter, 6-in. PFT-622• Sieve, 850 micro-meters PFT-623• Cone PFT-621• Brush, 7/8 rd. all metal, 302 S/S PFT-628

PFT Sieve Kit for Small Cell PFT-627• Adapter, 5-in. PFT-624• Sieve, 425 micro-meters PFT-625• Cone PFT-621• Brush, 7/8 rd. all metal, 302 S/S PFT-628

I.2 Utilities

Input Voltage: 90-265 VACInputFrequency: 47-63HZPower consumption: 150VACFuse: Two 2 AMP, 5 x 20mm, FAST-ACTING

Power Cord Color Code: United States Outside United StatesHot(live) Black BrownNeutral White BlueGround(earth) Green Green/Yellow

I.3 Specifications

Load for verticalaxis compression: 7 kg Accuracy: +/-0.6% of full scale range

Torque: +/-7.0N•m Accuracy:+/-1.2%offullscalerange

Distance: Accuracy +/- 0.3 mm

Torsionalspeed: 1revolutionperhour(RPH)upto5RPHwith0.1RPHincrements. Default setting 1RPH When using Keypad: 10 RPH

Axial speeds: 0.1 mm/sec up to 5 mm/sec with 0.1 mm/sec increments. Default setting 1 mm/sec

When using Keypad: 5 mm/sec


Temperature: Requiresoptionaltemperatureprobe(PartNo.DVP-94Y). -20°C to 120°C. Accuracy +/- 1.0°C.

HumiditySensing: Requiresoptionalhumiditysensor(PartNo.PFT-607Y). 10%to95%RHAccuracy+/-3%(35-75%RH), +/-5%(<35%RH,>75%RH)

Output: USB Port or RS-232 compatible Serial Port

Particle Size: The maximum particle size for the Standard Volume Shear Cell is 1 mm, assuming a relatively monosized material. A small size fraction at 2 mm with 90% below 1 mm is acceptable.

For the Small Volume Shear Cell, the maximum particle size is 250 micron, assuming a monosized material. A small size fraction at 500 micron with 90% below 250 micron is acceptable.

Environmental Conditions: 0°Cto40°Ctemperaturerange(32°Fto104°F) 20%-80% relative humidity, non condensing atmosphere

Use: Intended for indoor use only. Altitude up to 2000 meters

Dimensions: 36.2cm(141/4”)Wx39.7cm(155/8”)Dx67.6cm(265/8”)H (SeeFigureI-1)Weight: 34kg(75lb)

Minimum System Requirements for the Powder Flow Pro software: Microprocessor: 2GHz processor Memory: 512 MB of RAM Hard Drive Space: 30 MB available Video: 1024 x 768 resolution, 128 MB of graphics memory Operating System: Windows XP or aboveCommunications Port: One USB or RS-232 port


I.4 Dimensions

14 1/4"[36.2 cm]

15 5/8"[39.7 cm]

26 5/8"[67.6 cm]

14 1/4"[36.2 cm]

15 5/8"[39.7 cm]

Figure I-1: PFT Dimensions


I.5 Safety Symbols and Precautions

Safety Symbols

Refertothemanualforspecificwarningorcautioninformationtoavoidpersonalinjuryor damage to the instrument.

Keephands,fingersandotherbodypartsclearofmovingpartswhenoperatinginstrument.

Functional Earth Terminal Main power entry module must have an earth conductor, to ensure against electronic failure.

Precautions

Ifthisinstrumentisusedinamannernotspecifiedbythemanufacturer,theprotectionprovided by the instrument may be impaired.

This instrument is not intended for use in a potentially hazardous environment. In case of emergency, turn off the instrument and then disconnect the electrical cord from

the wall outlet.

The user should ensure that the substances placed under test do not release poisonous, toxic,orflammablegasesatthetemperaturewhichtheyaresubjectedtoduringthetest.

Thetorquereactionsensorwillbedamagedifmorethan150%oftheFSRtorque(+/-7.0N•m)isapplied.


I.6 Back Panel

jk

l

mnRS232 USB

TEMP HUMIDPOWER

%RH

1. KEEP ALL PACKAGING MATERIAL for future transit. The PFT must be shipped via FREIGHT! 2. The Trough, Trough Shipping Foam and Vane Lid must be installed into the PFT prior to shipment. (Refer to the manual for details.) 3. Contact Brookfield Engineering for replacement packaging.

Figure I-2: Back Panel

1. USB Type B port Use with USB Cable P/N DVP-202 to connect instrument to a computer. Cable USB 2.0

A Male to B Male. 2. RS-232 Serial Port

Use with RS-232 Cable P/N DVP-80 to connect instrument to a computer.3. Temperature Probe Plug

4-Pin plug. Use with Temperature Probe P/N DVP-94Y.4. Humidity Sensor Plug

3-Pin plug. Use with P/N PFT-607Y.5. Power entry module:

ON/OFFswitch-fused(seeUtilitiessection)Voltage90-265VAC.

6. Hand Hold locations for handling instrument. Recommend two people for movement of instrument due to heavy weight.

7. Label with the instructions for shipment of unit by freight carrier.


I.7 Key Functions

Bubble Level Access Door.

Lift flap to view Bubble Level

Test Stop Button

POWER

Figure I-3: Control keys for standalone mode

The control keys are used only for manual positioning of the compression lid assembly and the sample trough drive. Powder Flow Pro™Softwareisrequiredforallotheroperations.

Keypad

This key is used to move the compression plate assembly UP away from the sample trough drive assembly. It is also commonly used for general purposes.

This key is used to move the compression plate assembly DOWN towards the sample trough drive assembly.

PThis key is used to rotate the sample trough drive assembly clockwise. Note: This key is also used during calibration.

QThis key is used to rotate the sample trough drive assembly counter-clockwise. Note: This key is also used during calibration.

I.8 Test Stop - Reset

This button is used in case of an emergency situation. When this button is depressed, all software control is blocked and movement halts. Note that the manual control buttons on the instrument can still be used to reposition the lid and trough as necessary. Once the emergency situation is cleared, this button must be rotated to reset. After using the Test Stop button, both the instrument and the software should be restarted to ensure that normal communications have been reestablished.


I.9 Installation

Please follow the instructions listed below to unpack the PFT. This instrument is a sensitive load measuring device. It should be installed on a clean, solid, level bench surface which is free from external vibrations.

1. UnpackthePowderFlowTester(PFT)fromtheshippingcontainer.Todothis,cutthestrapsfrom the box and pallet.

Note: PLEASE RETAIN ALL PACKAGING MATERIALS FOR FUTURE USE. Refer to Appendix C for packing the PFT for shipment.

2. Cut the packaging tape on the box top.

3. Open the box top and remove the accessory box.

4. Remove the top foam piece.

5. Remove the outer box by lifting it up.

6. Open the plastic bag top and slide it down to the bottom of the PFT.

7. HandHoldlocationsarelocatedonthebottomandthebackofthePFT.(SeeFigureI-4)

Lift Here Lift Here

Lift Here Lift Here

Figure I-4: Back View of Hand Hold locations

8. Lift the PFT out of the packaging by using the Hand Holds. Lift the PFT from the bottom Hand Hold and guide the PFT with the back Hand Hold.

ThePFTweighs34kg(75lb).Usecautionwhenliftingtheunitoutofthepackaging.

9. Place the PFT on a clean, sturdy and level surface.


10. SAVE ALL PACKING MATERIALS, INCLUDING THE TROUGH FOAM INSERTS.

11. Position the instrument so the AC power switch is easily accessible. TheACinputvoltageandfrequencymustbewithintheappropriaterangeasshown

onthemodelandserialtagoftheinstrument(locatedonthebackofthePFT).

12. Make sure the AC power switch located in the back of the instrument is in the off position. Connect the power cord to the socket on the instrument and plug it into the appropriate AC line. Turn the power switch on.

13. Removethehorseshoeshapedfoamcollar(PFT-104)fromtheareadirectlyabovetheCompression Plate.

Horseshoe ShapedFoam Collar

Figure I-5: Removal of foam collar

14. Press the Up arrow key to raise the Compression Plate.

15. Remove the Sample Trough by lifting it up off of the Drive Disc on the instrument.

16. Remove the foam piece in the Trough.

17. Remove any additional components from the shipping package. Save the shipping container and packaging for future use.

18. Connect the USB cable to the slot designated for the USB in the back of the instrument. If RS-232 is used instead of USB, connect the cable to the RS-232 slot.

19. Connect the other end of the USB or RS-232 cable to a computer.

20. The PFT must be leveled. Open the bubble level access door. Adjust the four feet until the bubble is centered within the circle of the bubble level; also check to ensure the instrument is stable.Usea3/8"wrench(suppliedintheStandardAccessorykit)ortilttheinstrumenttoadjust the feet by hand.


I.10 Cleaning

Instrument and Keypad:Clean with a dry, nonabrasive cloth. Do not use solvents or cleaners.Use a vacuum cleaner to remove excess powder sample.

Do not use compressed air to clean the PFT.

Troughs/Lids/Catch trays:Theseaccessoriesaremadefromavarietyofmaterialsrangingfrommetals(stainlesssteel,Aluminum)toplastics(Tivar88,Teflon).Cleanwithanonabrasiveclothusingsolventsthatare appropriate for both the sample material and the material of the accessory.

Do not apply excessive force to the compression lid assembly or the sample trough drive assembly on the instrument. Damage may occur to the components.

Some of the accessories have sharp edges.


II. QUICK START PROCEDURE

1. Level the instrument. 2. Turn on the power to the instrument. The switch is on the back side. 3. Open Powder Flow Pro software application on PC. Go to the setup tab. Establish communication

withtheinstrumentbypushingthesearchbutton.Thecommunicationor“COM”portwillautomaticallybeselectedandidentified.

4. RecordtheweightoftheTrough(e.g.702.34grams).

Pin in Trough

Figure II-1: Trough

5. Attach the Outer Catch Tray outside the trough. Insert the Inner Catch Tray with Shaping Blade inside the Trough. The Inner catch tray locks into place with slight rotation. The pin in the Trough engages with one of the multiple pinholes in the bottom of the Inner Catch Tray.

InnerCatch

Tray

OuterCatch

Tray

Figure II-2: Inner and Outer Catch Tray 6. Fill the Trough with powder and level with the Shaping Blade; use the Shaping Blade with a

curvedprofilefortestusingaVaneLid;usetheShapingBladewithaflatprofilefortestusinga Wall Lid.

Figure II-3: Shaping Blade with curved profile Figure II-4: Shaping Blade with flat profile


7. Remove both catch trays.8. Record the weight of the powder and the trough. Subtract the weight of the trough to determine

the weight of the sample.9. Install the trough onto the instrument. Rotate the Trough by hand until the pinhole on the

bottom of the Trough engages the pin on the PFT turntable. The Outer Catch Tray can be installed on the trough to catch spillage during the test.

II-5: Powder Flow Tester

10. Attach the appropriate Lid to the instrument. Use Vane Lid for the Flow Function test and Time Consolidated Flow Function test. Use the Wall Friction Lid for the Wall Friction test and the Bulk Density test.

Figure II-6: Vane Lid Figure II-7: Wall Friction Lid

11. Go to the Powder Flow Pro software application. Enter the sample information and the weight of the powder sample under the tests tab. This information cannot be changed once the test has started.


Figure II-8: Sample Identification and Test Selection

12. Select the desired test method, e.g. Standard Flow Function. The default settings for the numberofConsolidationStresses(5)andnumberofOverConsolidationStresses(3)willautomatically appear. "Geometric Spacing" for the Consolidation Stresses is the default setting for Standard Flow Function.

Push DISPLAY TEST STRESSES button for a detailed list of the test steps.

Test StressesAppear HereDisplay Test

Stress Button

Figure II-9: Flow Function Test

13. Start the test by pushing the RUN TEST button. The lid will move downward to the position above, but not touching the sample. The instrument performs an automatic check on position andlead/torquesensorcondition.Duringthisself-checkprocedure,thelidwillbounceupand down for several seconds. When completed, the lid will move downward to make contact with the powder sample.

14. The Analysis Tab becomes active during the test. The real time display shows the axial load applied to the powder used to calculate the consolidation stress, and the torsional torquemeasured used to calculate the failure strength of the powder. The test runs automatically to


completion.Savethetestresultsunderthefilenamewhichyouselectedwhenenteringthetest sample information.

15. After the completion of the test, the lid will automatically lift off of the sample. Use the manual controlonthefaceoftheinstrumenttoraisetheLid(UPARROW)tofurtherraisetheLidtothe top of its range. Remove Lid from instrument. Remove the Trough from the instrument. Clean off the excess powder on the instrument.

16. Clean the trough and lid.


III. SAMPLE PREPARATION AND HANDLING

Accurateandrepeatabletestresultsrequireattentiontoconditionofthesamplepriortotestingand the use of proper laboratory procedures during sample preparation. This section explains the details.

III.1 Sample Issues

TheFlowFunctionandTimeConsolidatedFlowFunctionTestsrequireslightlyover260ccof sample material. Allowing for spillage during sample preparation and testing, best practice suggests that you start with at least 300 cc of sample material. If repeated tests will be performed on the same sample, then 500 cc or more are recommended.

Note the condition of the sample prior to testing. Storage in a bag or sealed container will offer protection, whereas leaving the sample on the counter in an open bag or container will expose the sampletotheenvironmentalconditionsinthetestarea.Ifthesamplehas“lumps”or“clumps”ofmaterial,spreadthematerialoutinaflatpanandgentlybreakthelumps/clumpsupsothatthe powder is more uniform in nature. Use a spatula, spoon or scoop to accomplish the “breaking up”action.Alternately,usethePFTSieveKittoremovelumps/clumps.SeeFigureIII-1.

Sieve- For Standard Volume Shear Cell PFT-623 (850 microns)- For Small Volume Shear Cell PFT-625 (425 microns)

Adapter- For Standard Volume Shear Cell PFT-622 (6-in. dia.)- For Small Volume Shear Cell PFT-624 (5-in. dia.)

Cone- For Standard Volume Shear Cell PFT-621- For Small Volume Shear Cell PFT-621

Trough- For Standard Volume Shear Cell PFT-400 (6-in. dia.)- For Small Volume Shear Cell PFT-405 (5-in. dia.)

Figure III-1: Sieve Kit (separated)

Use PFT-626 with the Standard Volume Shear Cell and PFT-627 with the Small Volume Shear Cell.


Moisture in the sample is one of the primary factors to be aware of when working with powders because it can have a serious impact in making the powder more cohesive, and therefore lessfree-flowing. Thepotentialfor thepowdertotakeonmoisture(eitherbyadsorptionorabsorption) isafactor thatcanaffect test results. ThePowderFlowTesterhas theoptionalcapabilitytoaccommodateahumiditysensor(PartNo.PFT-607Y)whichplugsintothebackof the instrument.Temperature may have some impact, but certainly plays less of a factor compared to humidity. ThePowderFlowTesterhastheoptionalcapabilitytoaccommodateatemperaturesensor(PartNo.DVP-94Y)whichalsoplugsintothebackoftheinstrument.Consider all environmental issues in your test area before proceeding with your test plan.

III.2 Sample Trough

There are two sizes of Troughs available for use with the PFT: The Standard Trough and the Small Sample Volume Trough.

FigureIII-2showstheStandardSampleTrough(PartNo.PFT-400)whichcomeswiththePFT.The trough is made of aluminum and is of annular shape for containment of sample. In the bottomofthetroughisaPerforatedScreen(PartNo.PFT-440)whichholdsthesampleinplaceso that the powder particles on the bottom do not slide on the smooth metal surface when the trough rotates.

PerforatedScreen

Figure III-2: Sample Trough

WhentheStandardTroughisfilledtolevel,itholds230ccofsamplematerial.WhenusedwiththeStandardVaneLid,theadditionalvolumerequiredfortheLidincreasesthetotalsamplesizeto 263 cc of material.

TheSmallSampleVolumeTrough(PartNo.PFT-405)isofthesamematerialasthestandardtrough.TheSmallTroughrequires38ccofsamplematerialwhenfilledtolevel.Whenusedwith the Small Vane Lid, the total sample size increases to 43 cc.


III.3 Lid Selection

The PFT comes with two types of Lids of annular design as shown in Figure III.3. The bottom side of the Lid is shown in each case; these surfaces make contact with the powder during the test.

Vanes

Figure III-3: Bottom side of Vane Lid and Wall Friction Lid

TheStandardVaneLid(PartNo.PFT-500)has18smallcompartmentswhichtrapthepowderparticles and cause them to shear against the powder particles in the Trough. The Vane Lid is madeof304s/sandhasa15.25cm(6-inch)outerdiameter.TheSmallVaneLid(PartNo.PFT-515)issimilarindesignandconstructionwitha12.7cm(5-inch)outerdiameter.

TheStandardWallFrictionLid(PartNo.PFT-507)hasasmoothbottomsurfacemadeof304s/swith2Bfinish,whichslidesoverthepowderparticlesintheTroughduringthetest,therebymeasuring the friction of powder against the surface material of the Lid. The surface can be madeofothermaterials,dependingonyourpreference;Mildsteel(PartNo.PFT-512)andTivar88(PartNo.PFT-513)aretwoothercommonoptions.Thechoicetypicallydependsonthematerial of construction that will be used in the storage bin, hopper or containment vessel that storesthepowderinyourprocessingplant.ContactBrookfieldoryourauthorizeddealerforalternative choices on the surface material of construction for the Wall Friction Lid. The Small WallFrictionLid(PartNoPFT-516)isalsoavailableinMildsteel(PartNo.PFT-522)andTivar88(PartNo.PFT-520).

The top sides of the Lids have two pins which engage with the Compression Plate on the instrument during the attachment process. Align the pins with the holes on the compression plate and press up to attach. Two release buttons must be pressed in order to remove the Lid from the Compression Plate.

Engagement Pin

Engagement Pin

Figure III-4a: Top Side of Lid Showing Engagement Pins


Release Button Hidden

Release Button

Compression Plate

Figure III-4b: Release Buttons Figure III-4c: Close-up of Compression Plate Holes

III.4 Outer Catch Tray

The Outer Catch Tray, shown in Figure III.5, provides a convenient apron around the trough for collection of sample material which spills over the edge of the trough during sample loading and testexecution.Centeritoverthetroughandobservethatitfitsconvenientlyontheouterlipofthe trough. This applies to both the Standard and the Small Sample Volume Troughs.

Sample Trough

Outer Catch Tray Figure III-5a: The Outer Catch Tray by Itself Figure III-5b: Outer Catch Tray on the Trough


III.5 Inner Catch Tray with Shaping Blade

TheInnerCatchTrayisusedtodistributethesampleevenlyinthetrough.Itfitsintotheannularopening on the trough. See Figures III-6a and III-6b.

Figure III-6a: Inner Catch Tray with Shaping Blade in Position to use Curved Profile

Figure III-6b: Inner Catch Tray Inserted Into the Annular Opening of the Trough

SampleTrough

Outer CatchTray

Inner CatchTray

Plow

TheShapingBlade,whichisaffixedtothecenteroftheInnerCatchTray,isrotatedbyhandtodistribute the sample. Note that the Shaping Blade can be removed by unscrewing the thumb screw that secures it to the Inner Catch Tray. This allows the user to choose the type of scraper bladethatisneededforsampledistribution.NotethatonesideoftheShapingBladeisflat(forusewithWallLidintheWallFrictionandBulkDensitytests)andtheotheriscurvedwhichpermitsmoundingofthesampleinthetrough(forusewiththeVaneLidintheFlowFunctionandTimeConsolidatedFlowFunctiontests).SeeFigureIII-7.

Curved Profile

Flat Profile

Thumb Screw

Figure III-7a Figure III-7b

Figures III-7a and III-7b Show the Two Positions of the Shaping Blade

III.6 Loading the Trough with Sample NOTE: Be sure the Outer and Inner Catch Trays are removed.

WeightheTroughbeforefillingitwithsamplematerial.Recordthevalue.


Place the Outer Catch Tray into position on the trough. Place the Inner Catch Tray into position onthetrough,thiswilllockintoplacewhenproperlyseated.UsethePowderScoop(PartNo.PFT-611),whichcomeswiththeinstrument,toplacethepowdersampleintheTrough.AnyspillageisconvenientlycapturedbytheInnerandOuterCatchTrays.Whensufficientsamplehas been placed in the trough, rotate the Shaping Blade on the Inner Catch Tray to distribute the sample evenly around the trough. Rotate in a clockwise direction until the sample is completely distributed. Then rotate in a counter-clockwise direction to remove excess sample.

An alternate loading procedure was explained earlier in Section III.1 when the Sieve Kit is used. Repeat the steps in the preceding paragraph once the Trough is full with powder.

Remove the Inner and Outer Catch Trays from the trough. Return excess sample material in the Catch Trays to the container from which the powder came or throw it away in accordance with your lab policy.

III.7 Placement of the Trough and Lid on the Instrument

Take the trough loaded with sample material and weigh it again. Subtract the weight of the Trough to obtain the weight of the sample material. Enter this value into the Sample Information section of the main screen on the Powder Flow Pro software.

Make sure that the Compression Plate on the instrument is in the upmost position. Use the Up arrow on the instrument control panel to reposition the Compression Plate if necessary.Place the trough on the Drive Disc of the instrument so that the center of the trough aligns with the pin in the center of the Drive Disc. Rotate the trough by hand until the pin on the outer edge of the Drive Disc engages one of the holes on the bottom of the Trough’s outer edge. When this occurs,thetroughwillliesecuredinaflatposition,centeredonthedriveplate.

Take care not to disturb sample.

Place the Outer Catch Tray in position around the trough. This serves to catch any spillage of the sample material when the test is running.

Attach the appropriate lid to the Compression Plate on the instrument. You may choose to do this before placing the trough on the instrument. It is simply a matter of operator preference.

The Lids are sharp. Be careful when installing and removing.

The test is now ready to begin. Refer to the section on Powder Flow Pro Software for details on running tests from your PC. When the Run Test button is pushed on the main screen, the Lid will automatically descend onto the Trough, pausing for a brief period of time just prior to making contact with the powder sample in order to perform an autozero.

Be sure to clean pins of the lids and compression plate to ensure proper alignment.


III.8 Removal of Trough and Lid from Instrument

When the test is complete, the Lid will automatically raise up a small distance off of the trough. This is a visual indication that the test has ended. Push and hold the UP arrow on the instrument control panel until the Lid has raised to its upmost position. Then disengage the Lid from the CompressionPlatebypressingthereleasebuttons(SeeFigureIII-3b).Cleantheexcesspowderthat clings to the Lid.

Remove the Outer Catch Tray from the trough and dispose of the excess powder in the Tray. Remove the trough from the instrument and dispose of the powder sample in accordance with labprocedure.CleantheTroughwiththeCleaningBrush(PartNo.PFT-612)whichcamewiththe instrument.

Notethattheperforatedscreenmayrequirespecialattentionwithpowderparticlesthathavebeen trapped in the openings. To remove the perforated screen, unscrew the three screws located underneath the trough.

III.9 Clean-up

The Cleaning Brush serves to remove excess powder from the Trough and Lid. This may be adequateforrepeatedtestingofthesamepowdertypeswherethepotentialforcross-contaminationbetween samples is not really an issue. Be sure to clean pins of the lids and compression plate to ensure proper alignment.For more thorough cleaning, the use of an air hose, water, or a cleaning solvent may be desired. Whenusingaliquidforcleaning,makesuretodrytheTroughandLidthoroughlysothatmoisturecontamination does not become an issue with the next sample.

Do not use compressed air to clean the PFT.


IV. POWDER FLOW PRO SOFTWARE

PowderFlowProSoftware(PartNo.PFT-609)andaUSBcableforconnectiontoaPCareprovidedwiththePFTinordertooperatetheinstrument,collectdata,performanalyses,storedatafiles,andexport data to Excel™. Connect the USB cable to the PFT and to your PC. Turn on the PFT using the power switch on the backside of the instrument. Once the PFT is on, start the software by clicking the Powder Flow Pro icon on the start/program bar.

IV.1 Main Screen and Setup Tab

Upon startup, the Tests Tab screen comes up as shown in Figure IV-1.

Figure IV-1: Tests Tab Screen

Details on sample type and test method are entered on this page. However, before proceeding, make sure that the program is communicating with the PFT by clicking on the Setup Tab. The Setup Screen is shown in Figure IV-2.

Figure IV-2: Setup Screen


Pressthe“Search”button.Youcanalsoselect“Search”fromthecommunicationsdrop-downbox.IftheinstrumentiscorrectlyconnectedtoyourPCwiththeUSB(orRS-232)cable,thegreenlightwillcomeonandthetypeofcommunicationportbeingusedwillbeidentified,in this case, USB.While on this page, it is also possible to adjust the measurement units, axial speed for moving the lids up and down, and torsional speed for rotating the trough. Default values are set at the factory for measurement units and operating speeds. If you decide to change any of these values, you must then shut down the Powder Flow Pro program and start it up again in order for the changes to take effect.The setup tab also contains the different lid descriptions and part number to help correctly choose thelidthatfitsthetestbeingrun.ThelidcanbechangedintheTestTabunder“TestOptions”.Click the Tests Tab, which brings you back to the Main Screen.

IV.2 Sample Information

The left column on the Main Screen is used to enter information on the sample that you are testing. See Figure IV-3.

abcd

e

becomesfilename

Figure IV-3: Close-up of Left Column on Main Screen

There are 5 boxes in which to make entries:

a) SampleTemplate E.g.MaizeFlourb) ProductName E.g.Smith’sMaizeFlourc) BatchNumber E.g.Listyourcontrolnumberforthesampleor,perhaps,the

date time if you don’t use control numbers.d) SampleNumber:Youhavethechoicetoallowthesoftwaretoincrementeachtestwith

asequentialcontrolnumber(thedefaultsetting),oryoucanchoosetosetthisvaluebyclickingthe“SetManually”button.

e) Weight:Entertheweightofthesample.Thedefaultsettingisgrams.


Sample Notes can be entered in the box on the bottom half of the left column on the Main Screen. This may provide information, for example, on how the sample was prepared or how long it has been in storage.

Clickon thedisc iconabove“Sample Identification” tosave the information thatyouhave justentered on your sample. This creates a sample template that can be used for future tests with the same information.

IV.3 Standard Test Method

This is the Default Test Method.

The middle column on the Tests Screen is used to select the type of test that you want to run. See FigureIV-4.ThedefaultsettingwhenfirstusingthePowderFlowProsoftwareis“Standard”forthe test Method.

Figure IV-4: Close up of Middle Column on Main Screen

Chooseoneofthetests.ThefirstfivetestsrequiretheuseoftheVaneLid.ThelastfourtestsrequiretheuseoftheWallFrictionLid.ThefirstfivetestspertaintoFlowFunction,thenextthreetoWallFrictionandthefinalonetoDensity.

Theadvantagetousing“STANDARD”testisthateachmethodfollowsgenerallyacceptedpracticeinindustryforevaluatingmostmaterials.Theresultingdatawillbeafairrepresentationoftheflowbehaviorofthematerialand/orthedensityasafunctionofconsolidation.Specificchoicesfortestparameters are not necessary because these values have automatically been built into the test and cannot be changed.


IV.3.1 The Flow Function Test

The Standard Flow Function Test employs 5 Consolidation Stresses using Geometric Spacing between each stress, 3 over consolidation stresses at each consolidation stress, and one special consolidation stressforthetestatthetangenttotheUnconfinedMohrCircle.(SeetheHelpfileinthesoftwareforadditionaldetailonthislaststatement.)

The Standard Flow Function Test runs 35 test conditions on one sample, to explore fully the complex behaviousofapowder.Thisgivesthehighestlevelofconfidenceintherelevanceofresultswhencomparingdifferentpowders.Itisinlinewithlong-establishedprotocols.BrookfieldrecommendstheStandardFlowFunctionTestasthebesttesttousewhenobtainingpowderflowdataforcomparingpowder behaviour, for Quality Control purpose, for equipment design/assessment or any otherpurposes,providedyoucansparethetimetorunit(around34minutes).

TheQuickFlowFunctionTests(5-pointand2-point)havebeendevelopedtogivefastertests(18minutesand14minutesrespectively)foruserswhocannotsparethetimetoruntheStandardFlowFunction Test and are happy with a less sensitive comparison between powders. They measure fewer testconditions(totalof6forthe2-pointand15forthe5-pointtest)sotheresultsdonotcapturethe full behaviour of the powder. Where the powders are more than about 10% different from one anotherinflowability,theseshorttestswillgiveusefulindicativecomparisons,butforpowdersthatare fairly close in behaviour, the differences may not be apparent.

DonotattempttocompareFlowFunctionsobtainedfromdifferenttests(E.g.2-pointagainststandard,or5-pointagainst2-point)becausethecomparisonislikelytobeincomplete.

TheQuickFlowFunctionTestsareexcellentfordoingafirst-stagescreeningifyouhavealargenumberofpowdersandyouwishtoquicklybracketthemintogroupsbyflowproperties(saytofind theones thataremost likely troublesomeanddeservemoredetailedmeasurements). Eventhe 2-point test will reliably indicate where there are substantial differences in behaviour between powders.Someusersfindtheycanusethe5-pointtestforQualityControlpurposes,toidentifybatches within a single production stream that could be troublesome. However, if you wish to use the“quick”testsforQC,BrookfieldrecommendsainvestigationinwhichyouruntheStandard,5-point and 2-point tests in parallel on a substantial number of production samples to ensure that thequicktestdoesindeedidentifyanydifferencesthatyouconsidersignificant.Onceyouhavesatisfiedyourselfthatthisisthecase,thenalwaysusethesametest(StandardFlowFunction,5-or2-pointQuickFlowFunction)forthatQCprocedure.Donotbetemptedtocomparedatabetweenthe three test types. As a general rule, the smaller the differences you are looking to discriminate, thenthelargerthenumberoftestpointsyouwillrequire.

Oncethetesthasbeenselected,clickonthe“DisplayTestStresses”buttontoviewthenumberofstepsinyourprogramasshowninFigureIV-5.Inthiscaseastandardflowfunctiontesthasbeenselected.Thetwocolumnsontherightshowthesequencefortheconsolidationstressesandthecorresponding overconsolidation stresses that will be applied. Note that the time estimate for the test to run is displayed in the window at the top right of the Main Screen. Units are hours:minutes:seconds.


Figure IV-5: Right Column on Main Screen

IV.4 Custom Test Method

Tocreatecustomtests,thetestmethodmustbechangedtoCUSTOMinthe“TestMethod”tabshown in Figure IV.4. To enable this custom test method, you must choose this from the advanced optionsundertheSetuptab(seeSectionIV.9toselectcustomtests).

Figure IV-6: Custom Test Method Screen


Details on information that you must enter for each test follow:a) Flow Function The user can set the maximum in consolidation stress to test to, the number of consolidation

stresses to test, whether to space the consolidation stresses evenly or geometrically, the number of over consolidation stresses to run at each consolidation stress, whether to use a new sample for each consolidation test, whether to repeat each stress measurement, and whethertotestatthetangenttotheUnconfinedMohrCircle.

b) Time Consolidated Flow Function The user can set the amount of time to consolidate at each consolidation step, whether

to use a new sample for each time consolidation, the maximum consolidation stress to test to, the number of consolidation stresses to test, whether to space the consolidation stresses evenly or geometrically, the number of over consolidation stresses to run at each consolidation stress, what stress to apply during time consolidation, whether to repeat each stressmeasurement,andwhethertotestatthetangenttotheUnconfinedMohrCircle.

c) Wall Friction The user can set the material of the wall lid, the maximum stress to test to, the number

of displacement levels to test at, whether to space the displacement levels evenly or in a doubling progression, the number of stresses to run at each displacement level, what stress to apply during wall displacements, and whether to use a new sample for each displacement level.

d) Bulk Density Curve The user can set the number of stress setpoints and the maximum stress to test to.

Clickonthedisciconabove“TestType”tosavetheinformationthatyouhavejustenteredontesttype. This creates a template that saves the test procedures for future use.

IV.5 Test Execution

Tostartthetest,clickthe“RunTest”buttonontheMainScreen.TheLidwilldescendtoaposition slightly above the sample in the Trough; the instrument will perform an autozero; then the Lid will make contact with the sample and the test begins.

The Raw Data Tab on the Analysis Screen will automatically come up and show the axial load test data and the torsional load test data. See Figure IV-7 for an example of the raw data generatedduringaflowfunctiontest.TheaxialloadunitsareshownontheY-axisontheleftofthegraph(redcolor)andthetorsionalloadunitsareshownontheY-axisontherightofthegraph(bluecolor).Theaxescanbechangedtotheuser’spreferencebyusingthedropdownboxes above the graph.


Figure IV-7: Image of Test Data on Analysis Screen Showing One Full Cycle of a Consolidation Stress and Four Associated Overconsolidation Stresses

Throughoutthetest,agreenlightwillflashandtheestimatedtimetocompletionwillcontinueto count down and be displayed in the top right window on your screen. The algorithms which measure peak torsional stress and steady state torsional stress have optimization functions built into the real time data analysis. The net result is that some of the test time may be reduced becausethesteadystatevalueisachievedearlierthantheallottedtesttimeforaspecificstep(s).Alternately, the test time may increase for the opposite reason, most notably in the Flow Function Testwhenestablishing“criticalconsolidation”atthebeginningofeachconsolidationlevel.

At any time during the test, the user can return to the Main Screen to observe the detailed test step display and note which step is in progress.

Whenthetestiscompleted,theflashinggreenlightwilldisappear,the“EstimatedTestTime”window will be blank, and the Lid will raise up slightly off the sample. The test step will say “TestComplete”.

Details on test method execution for each of the 4 test types are shown in the following figures.


Load powder, start test

Apply consolidation loadShear to steady state

Re-apply consolidation loadMeasure peak

Apply over-consolidation loadMeasure peak

Re-apply consolidation loadShear to steady state

Calculate tangent load

Apply tangent loadMeasure peak

Re-apply consolidation loadShear to steady state

Re-apply consolidation loadMeasure peak

End test, process results

Loop until allincreasing over-consolidationloads are tested

Loop until allincreasingconsolidationloads are taken

Loop until allrepeat over-consolidation measurementsare taken

(if option chosen)

Figure IV-8: Flow Function Test Algorithm.



Apply consolidation load,shear to steady state

Re-apply consolidation load, measure peak

Apply over-consolidation load, measure peak

Re-apply consolidation load, shear to steady state

Calculate tangent loadApply tangent load,measure peak

Re-apply consolidationload, shear to steady state


Leave for time consolidation period T, apply load σ

1

Apply Time over-consolidation load, measure peak

Load fresh powder sample(ifoptionischosen)

(if option chosen)


Loop until all increasing over-consolidation loads are tested

Loop until all repeat over-consolidation measurements are taken

Loop until all increasing consolidation loads have been tested

Figure IV-9: Time Consolidated Flow Function Algorithm



Apply compaction load,measure lid position

Apply consolidation load, shear to steady state


Apply Wall consolidation load,rotateforrequiredsheardisplacement


Loop until all increasing compaction loads are taken

Loop until all reducing consolidation loads are tested

Loop until all increasing wall displacements are measured

Figure IV-10: Wall Friction Test Algorithm



Apply compaction load,measure lid position


Loop until all increasing compaction loads are taken

Figure IV-11: Bulk Density Test Algorithm

IV.6 How to Stop the Test

In case of an emergency, hit the large red Test Stop Button on the instrument and use the manualcontrolkeystorepositionthelidandtroughasnecessary.(SeesectionI.7formore information.

In non-emergency situations, the user can abort the test by clicking on the Stop icon in the upper left corner of the main screen or by clicking the Stop Test button, which lights up on the Main Screen once the test starts. See Figure IV-12.

Figure IV-12: Stop Button on the Analysis Screen

When the Stop Test button is clicked, the Lid will lift up from the Trough, which is no longer rotating. The test is cancelled and cannot be resumed at the step where it was stopped. If the sample had been compacted, it is best practice to replace the sample with fresh material before starting a new test.


IV.7 Analysis Section IV.7.1 How to Save Data

Once the test has completed, you have the choice to save the raw test data and/or the calculated stressdata(clickontheStressDataTab).Mostuserswillchoosetosaveonlythecalculatedstressdata,sincethisisthebasisforcomputingthedesiredoutputparameters:flowfunction,friction angle curves, density curve and critical hopper dimensions. Therawtestdataconsistsof50datapointspersecond,whichmeansthatthefilesizecanbelarge, especially for tests of lengthy duration. For this reason, most users may choose not to save raw data.To save the calculated stress data, click the disk icon on the toolbar. To save the raw data, click theboxcalled“SaveRawData”locatednexttothediskicon,thenclickthediskicon;thiswillsave both the raw data and the calculated stress data.The graph may be saved separately as a bitmap by clicking the disc icon above the selected graph. To get the desired picture, the buttons above the graphs can be used to zoom in, zoom out, as well asscrolltheaxis.Rightclickingontheaxisgivestheoption“zoomtofit”whichcanbeaveryusefultool(forexample,insteadofsavingthehugerawdatafile,theusercanusethe“zoomtofit”featuretofittheentirerawdatasequenceandthensaveitasabitmapinstead.).

IV.7.2 Choices for Data Display

FigureIV-13showstheavailablechoicesfordatathatcanbedisplayed(RawData,StressData,FlowFunction,FrictionAngle,Density,HopperDesign)andtheformatfordisplayingthedata(Graph,Results,Data).Clickontheboxesthatyourequireandthecorrespondingdataand/orgraph(s)willbeshown.

Figure IV-13: Options for Data Output Display

When the test for Bulk Density Curve is selected, the tabs which appear include Raw Data, Stress Data, and Density.

Note that the different results are available depending on the type of test that was run. The Flow Function tab applies only to Flow Function and Time Consolidated Flow Function tests. Bulk Density tests include only Raw Data, Stress Data and Density.


Details on the information that can be viewed under each tab follows:

a) Raw Data: Alltesttypesdisplaythespecificfieldschosenfortherawdatagraph.

Figure IV-14: Raw Data Graph for Flow Function Test

b) Stress Data:

All applicable Peak and Steady State stresses are shown. In addition, the following is displayed for each type of test:

• Flow Function Test data shows a locus line for each Consolidation Stress setpoint, withcorrespondingUnconfinedandOverConsolidatedMohrcircles,andaSteadyState locus line. For the Steady State locus, the gradient, angle, and cohesion are reported. For each Consolidation Failure Locus, the Major Principal Consolidation Stress, Unconfined Failure Strength,Angle of Internal Friction, gradient, angle,cohesion, and density are reported.

• Time Consolidated Flow Function Test data shows all the instantaneous locus lines and circles, plus a time consolidated locus line for each Consolidation Stress setpoint withitscorrespondingUnconfinedMohrcircle.All instantaneousflowresultsarereported;eachtimeconsolidatedlocusreportsitsUnconfinedFailureStrengthandcohesion.

• Wall Friction Test shows one locus line for each Displacement setpoint and one Maximum Wall locus, including the gradient, angle, and cohesion for each locus line.

• Density Test data: Not applicable.


Figure IV-15: Stress Data Graph for Flow Function Test

Figure IV-16: Stress Data Graph for Wall Friction Test

c) Flow Curve:

• FlowFunctionTestshowsthecurveofUnconfinedFailureStrengthsversusMajorPrincipal Consolidation stress and reports the Flow Function gradient and intercept, the critical Arching and Rat-hole stress, and the Flow Index for a given stress.


Figure IV-17: Flow Function Graph

• Time Consolidated Flow Function Test shows the same results as the Flow Function Test, but shows one set of results based on the instantaneous Flow Function and one based on the Time Consolidated Flow Function.

Figure IV-18: Time Consolidation Test Graph

• Agraphofa“normalized”flowfunctionisobtainedbyselectingPotentialArchingDiameterfromthedrop-downlistboxlocatedabovethegraph.The“normalized”flow function provides a means for comparing powders that exhibit similar flow function behavior, but have different density properties. The graph plots “potential archingdiameter”against“majorprincipalconsolidatingstress”.Themathematicsinvolves dividing the density of the powder at each consolidation stress into the valuefortheunconfinedfailurestrength.


Figure IV-19: Normalized Flow Function Graph

• FlowFactor:Selectthesetuptab.Checkthebox“DisplayFlowIndex”.Adottedline appears on the Flow Function curve under the Analysis tab. This is referred to asthe“ArchingFlowFactor”.

The default value for the Flow Factor is 1.4; the value can also be selected by the user and normally ranges between 1.0 and 1.8 in design practice; choosing values below 1.4 shifts the Flow Factor line to give a steeper slope; choosing values above 1.4 shifts the Flow Factor line to give a lower slope.

If the Flow Factor line intersects the Flow Function curve, this point of intersection definesthe“criticalconsolidationstress”.

• Wall Friction Test data: Not applicable.


d) Friction Angle Curve:

• Flow Function Test data shows one curve based on the Effective Angle of Internal Friction for each Consolidation setpoint and reports the Effective Angle of Internal Friction for the critical Arching stress and critical Rat-hole stress.

• Time Consolidated Flow Function Test data reports the instantaneous Flow Function results along with the Effective Angle of Internal Friction for the Time critical Arching stress and Time critical Rat-hole stress.

• Wall Friction Test data shows one Wall friction angle curve for each displacement setting and one curve based on the Maximum Wall locus. The data tab lists all Wall


Friction angles, at each stress setpoint at each displacement setting, including the Maximum Wall Friction at each stress setpoint.


Figure IV-20: Friction Angle Graph for Flow Function Test

Figure IV-21: Friction Angle Graph for Wall Friction Test


e) Density Curve:

• FlowFunctionTestdatashowsonecurvebasedontheinitialfilldensityandthedensities measured at the Steady State stress values. The Density for the critical Arching stress and critical Rat-hole stress are also reported.

• Time Consolidated Flow Function Test data reports instantaneous results along with the Density for the Time critical Arching stress and Time critical Rat-hole stress.

• WallFrictionTestdatashowsonecurvebasedontheinitialfilldensityandthedifferent consolidation stresses during the test.

• BulkDensityCurveTestdatashowsonedensitycurveincludinginitialfilldensity.

Figure IV-22: Density Curve Graph

f) HopperDesign:

• Single values for Arching Dimension and Rat-hole Diameter are calculated automaticallyusingthe“CriticalConsolidationStress”.

• In Mass Flow, Arching Dimension and Hopper Half Angle are calculated. A graph of hopper half angle vs. hopper outlet dimension is given. The hopper outlet dimension isequivalenttothearchingdimension.


Figure IV-23: Hopper Half Angle vs. Hopper Outlet Dimension Graph

• In Core Flow, a Rat-hole Profile graph is generated showing powder depth vs. rat-hole diameter.

Figure IV-24: Powder Depth vs. Rat-Hole Diameter Graph

• Time Consolidated Flow Function Test data shows two sets of Arching and Rat-hole dimensions,onebasedontheinstantaneousflowfunctioncurve,andonebasedontheapplicabletimeconsolidatedflowfunctioncurves.Thereisanoptiontouseaseparatedensityfile.


Figure IV-25: Time Consolidated Flow Function Test Graph

• Wall Friction Test data allows the user to calculate several Hopper half angles, one foreachDisplacementsetpoint.TheuserselectstheFlowFunctiontestfileinorderto perform this calculation. Arching and Rat-hole dimensions are not applicable.


IV.7.3 How to Create a Data Report

Onceatesthasbeencompleted,theusercanviewananalysisreportbypressingthe“viewreport”button shown in Figure IV-26 in the analysis tab. The user can customize the report by checking the boxes below as needed. A report of the corresponding data will be created in tabular format.

Reports can also be created for comparisons and statistics using the same procedure.

Figure IV-26: View Report Screen


IV.7.4 How to Compare Data

Data sets can be compared using the comparison tab. A user can open up to eight data sets for comparison by double-clicking on the open slots and selecting a data set from the database. Graphs as well as tabular data can be created to show the comparison of like output parameters. Forexample,iftheuserwantstocomparetheflowfunctiongraphofmanydatasets,onlyflowfunction test sets can be selected.

Blank Page Icon

Export to Excel Icon

Figure IV-27: Comparison Graph for Data Sets

Tocleardatasetsfromthelist,highlightoverthechosendatasetandhitthe“BlankPageicon”to erase it from the list. The user also has the ability to export the comparison report to Microsoft Excel™byusingthebottombuttonwiththe“arrowicon”.

Comparisonsbetweendatafilesaredoneusingoneconditionfromeachfile.Thereareseveraloutput parameters to consider. For example, only the Time consolidated values from a Time ConsolidatedFlowFunctiontestarecomparedtootherfiles.TheinstantaneousvaluesfortheTime Consolidated Flow Function test are not used in the comparison.

a) FlowFunctionCurves: • For Flow Function Test data, the regular Flow Function curve is used for comparisons.

This reports the gradient, intercept, critical stresses, and Flow Index based on this Flow Function.

• ForTimeConsolidatedFlowFunctionTestdata,thetimeconsolidatedflowcurveisused for comparisons. This reports the gradient, intercept, critical stresses, and Flow Index based on this Time Consolidated Flow Function. If you want to compare the instantaneous and time curves within a single Time Test data set, you can do so in the Analysis section.

• Wall Test data: Not applicable.• Density data: Not applicable.

b) FrictionAngleCurves:• For Flow Function Test data, the Internal Friction Angle curve is used for comparisons.

This reports the Internal Angles at critical stresses based on this curve.• For Time Consolidated Flow Function Test data, the Time Consolidated Internal


Friction Angle curve is used for comparisons. This reports the Internal Angles at the Time critical stresses based on this curve. If you want to compare the instantaneous and time critical stresses within a single Time Test data set, you can do so in the Analysis section.

• For Wall Friction Test data, the Wall Friction Angle curve from the Maximum Wall Locus is used for comparisons. If you want to compare Wall Friction Angle curves at different displacements within the same data set, you can do so in the Analysis section. If a Wall Test data set is part of the Comparison, no angles are reported for criticalstresses,becausethecriticalstressesfortheWallfileareunknown.


c) BulkDensityCurves:• For Flow Function Test data, the densities measured at the steady state of each locus

line is used for comparisons. This reports densities at critical stresses for arching and rat-holing.

• For Time Consolidated Flow Function Test data, the instantaneous density curve is used for comparisons. This reports densities at critical stresses for arching and rat-holing.

• For Wall Friction Test data, the density data from the different consolidation stresses during the test are used for comparisons. If a Wall Test data set is part of the Comparison, no densities are reported for critical stresses, because the critical stressesfortheWallfileareunknown.

• For Bulk Density Test data, the density data from the compactions are used for comparisons. If a Density Test data set is part of the Comparison, no densities are reported for critical stresses, because the critical stresses for theDensity file areunknown.

d) HopperDesign:• For Flow Function Test data, the critical values from the regular flow function,

friction angle, and bulk density curves are used for comparisons. There is no external DensityfileoptionvaluesaretakenfromwithintheFlowFunctionTestdatafile.

• For Time Consolidated Flow Function Test data, the critical values from the time consolidatedflowcurve areused for comparisons.Use the instantaneous frictionanglealongwiththedensitycurves.ThereisnoexternalDensityfileoption.Ifyouwant to compare instantaneous and time consolidated outlet sizes within one Time Test data set, you can do so in the Analysis section.

• Hopper Half Angle is not included in the Comparison section, because each calculationrequiresspecifyingtwodatasets,aFlowFunction(orTimeConsolidatedFlowFunction)TestandaWallFrictionTestdataset.

• Rat-Hole Diameter and Arching Dimension values are displayed for each data set. TogetatrueRat-Hole,theBinDiameterandHeight(PowderHeight)valuemustbeinput. For Arching Dimension, choose either Conical or Plane for the proper hopper outlet.


IV.8 Statistics Page

Statisticscanbedoneonresultswhichhaveonevalueperdatafile.Forexample,statisticscanbe done on the slope and angle of the Steady State Failure Locus of 10 Flow Function Test data sets, because each data set has only one Steady State Locus gradient. Statistics could not be done on the Time Consolidation Flow Function Failure Locus gradient, because there are several Consolidation Failure Loci per data set. Up to 30 data sets can be compared.

Figure IV-28: Results Available for Statistical Analysis

The statistics tab can be used to compare different values among many data sets. Reports can becreatedcomparingstatisticson“SteadyStateFailureLocus”,“FlowFunction”,“Arching”,“Rat-Hole”,and“Density”.

Refer to Figure IV-29 for an example of several Flow Functions Tests on Limestone Sand.


Figure IV-29: List of Limestone Sand Flow Function Data and Results for Statistical Analysis

See Figure IV-30 for an example of the Statistical Report for the Limestone Sand.

Figure IV-30: Example of Printout for a Statistical Report

The following statistical reports can be created for the types of test data as indicated:

• Statistics for Flow Function and/or Time Test data sets: Statistics can be done on the following results: Steady State Locus gradient, angle,

and cohesion; Flow Function gradient, intercept, and Flow Index at a given stress; Arching dimension and critical arching stress, friction angle, and density; Rat-hole diameterandcriticalrat-holestress,frictionangle,anddensity;fillbulkdensityandmaximum bulk density.

• Wall Friction Test data sets: Statistics can be done on the Maximum Wall locus gradient, angle, cohesion and

angleatagivenstress,fillbulkdensityandmaximumbulkdensity.

• Bulk Density Test data sets: Statisticscanbedonethefillbulkdensityandthemaximumbulkdensity.


IV.9 Setup Page

The setup page allows the user to change the measurement units and select from a list of Advanced Options. Advanced Options allow the user to display a Custom Tests option under the Test tab. For a Custom Test method, set Pass/Fail limits on the Flow Function graph, display a Flow Index foradefinedMajorPrincipleConsolidationStressunderaFlowtest,adjusttheArchingFlowFactorfortheHopperDesign,andchooseaSeparateDensityFile(ratherthanaWallFrictionfile)foraHopperHalfAnglecalculation.

Figure IV-31: Advanced Options

TheDataFileManagementiconallowstheusertoimportandexportdatastressfiles,exporttoExcel and backup and archive data.

Figure IV-32: Data File Management

Data can be exported or imported by clicking the appropriate icons at the top of the Analysis tab (‘arrowleavingpage’iconforexportand‘arrowenteringpage’forimport).

DatafilescanbeexportedtoeitheranExcelformatorinanExternalStressDatafileformat,called“.ADTG”,whichutilizestheAccessDatabase.

The“.ADTG”fileformatcanbeusedtotransferdatafilesfromonecomputertoanother,bothcomputers must run Powder Flow Pro software:

1) ExportthedatafileasanExternalfile(*.ADTG).2) MovetheresultingExternalfiletotheothercomputer.3) Importthefileusingthatcomputer’sPowderFlowProsoftware.


IV.10 Custom Page

The custom tab can be used to look at control windows by making the user’s own customized display. Control windows can be moved into the custom page by either right clicking or selecting the desired windows from the pop-up list or by undocking the control window, which can be done by double-clicking the bar on the top or left of the window, and dragging it to the Custom Page. See Figure IV-33.

Figure IV-33: Custom Page

IV.11 Help Files

Helpfilesare located in thePowderFlowProSoftware in the top leftcornersignifiedbya“questionmarkicon”.ThesefileswillhelptheusergetabetterunderstandingonhowthePFTworks. The help section also helps guide the user in setting up and running an accurate test.

Figure IV-34: Help Icon


Appendix A: Overview of Powder Flow Properties

Problems with Powder that relate to Gravity Flow Behavior

Atypicalindustrialpowderprocessinglinewillincludeseveralstoragevessels(e.g.bins,bunkers,silos,hoppers,IntermediateBulkContainers(IBCs),sacksetc),feedingorhandlingsteps(e.g.belt conveyor, screw conveyor, pneumatic conveyor, gravity chutes etc) andprocessing steps(e.g.milling,mixing,drying,baggingetc).Amajorindustrialproblemisgettingthepowdertodischarge reliably from storage into the next process step. Therefore to understand the application ofpowderflowmeasurements,itisusefultohavesomebackgroundknowledgeoftheflowpatternsandflowobstructionsthatcanoccurinsidethestoragevesselsonaprocessingline.

What are the powder flow patterns that can occur in a process storage vessel?

Principallytherearetwodifferentflowpatternsthatcanoccur:Core-flow(showninFigureA-1a)canbeconsideredthedefaultflowpatternandischaracterizedbypowderdischargethroughapreferentialflowchannelabovethedrawdownpointoftheoutlet.Powderisdrawnintotheflowchannelfromthetopfreesurfaceoftheinventory.Thisgivesafirst-inlast-outdischargeregimeand,ifoperatedonacontinuous(ratherthanbatch)mode,thepowder around walls in the lower section will remain static in the vessel until the time that it is drained down to empty. Mass-flow(showninFigureA-1b)isthedesirableflowpatternforpowdersthatarepoorflowingortimesensitive,butmustbespecificallydesignedfor.Heretheentirecontentsofthevesselare‘live’,givingafirst-infirst-outdischargeregime.Toachievethis,thehopperwallsmustbesufficientlysteepandsmooth.Foragivenwallmaterial/convergingangle,thepowderwallfriction must be below a critical value. Also, the product discharge must be controlled by a valve orfeederthatallowspowdertoflowthroughtheentirecrosssectionalareaoftheoutlet.(Itisthisfinalpointthatpreventsmanyvesselsfromoperatinginmass-flow.)A wall friction test will be able to give an approximate assessment of whether a given hopper geometrywillsupportmass-flow(withtheprovisothattheoutletareaisfullyactive).Foranexactcalculationof themaximummass-flowhopperhalfangle,bothwall frictionandflowfunction tests must be undertaken.

What are the powder obstructions that can occur to prevent flow?

Principallytherearetwodifferentflowobstructionsthatcanoccur:‘Rat-holing’ (showninFigureA-2a)istheprincipleflowobstructioninacore-flowvessel,wherethepowderintheflow-channelabovetheoutletdischargesleavingastableinternalstructure.‘Arching’ (showninFigureA-2b)istheflowobstructioninamass-flowvessel,whereastablepowder arch forms across the outlet or converging walls of the hopper, thereby preventing flow.

For a given powder there is a critical outlet dimension that must be exceeded to ensure reliable dischargeofacore-flowormass-flowvessel.Thesearethecriticalrat-holediameter DRH and the critical arching diameter Dc or Dp (dependingonthehoppergeometry). TheBrookfieldPowderFlowTester(PFT)cancalculate thesecriticaldimensionsfollowingaflowfunction


measurement.Anaccuratedimensionrequiresawallfrictiontestaswell.Notethatforagivenpowder,therat-holediameterissignificantlylargerthanthearchingdiameter.

What are the flow patterns that can occur?

Mass-flow

Flowing core

Drain down angle of repose

Static material

Critical rat-hole diameter

Core-flow

Figure A-1a: Core-flow Figure A-1b: Mass-flow

h

What are the forms of the flow obstructions?

Figure A-2a: 'Rat-hole' Figure A-2b: Arch

Conicalhopper

DC

Figure A-3a: Conical hopper Figure A-3b: Wedge (plane) hopper

DP L

Wedgehopper


Note: Twotypesofhoppershapeareconsidered:conicalhoppersandwedge(orplane)hoppers as shown in Figure A-3a & A-3b.

Key differences between powders and fluids

For any fluid the resistance to shear (viscosity) is independent of the normal pressure butdependent on the shear rate. In powders the effect of these factors is reversed so that shear stress of a powder is strongly dependent on the normal stress but independent of the shear rate. Hence when characterizing powders, test are undertaken at a single speed but over a range of normal stresses.Theotherkeydifferenceisthatpowdersareanisotropicsothestressesarenotequalinalldirectionsandarefrictionalsothattheycangenerateshearstressesatwallboundaries(seewallfrictionsection).

Flow function test

Theprimarymeasureofpowderflowabilityisthepowderflowfunction–whichgivesameasureof the amount of strength the material retains at a stress free surface following consolidation toagivenstresslevel.Thesimplestwayofexplainingtheflowfunctioniswiththeuniaxialunconfinedfailure testshowninFigureA-4,whichmeasures thestrengthofafreestandingcolumn of powder. This condition is analogous to the condition of the powder arch across a hopper outlet shown in Figure A-2b.

i) Consolidation of sample. Powder is placed in a cylindrical cell and compacted under a known normal stress σ1.

ii) Unconfined sample. The mold is now carefully removed to reveal a compacted column of powder.

iii)Unconfined failure of sample. The normal stress acting on the column of powder is gradually increased until failure occurs, and the peak normal stress σc is recorded.

σ1 σ3

σ3=0

Figure A-4: Uniaxial unconfined failure test

Theaboveuniaxialunconfinedfailuretestisconductedoverarangeofconsolidationstressesand the flow function is constructed by plotting the unconfined failure strength versus theconsolidation stress as shown in Figure A-5.


Non flowing Very

cohesiveCohesive

EasyflowingUnconfinedFailure

Stre

ngth

σc

Freeflowing

ff=1 ff=2

ff=4

ff=10

Major Principal Consolidation Stress σ1

Figure A-5: The powder flow function

The standard classification of powder flowability uses the flow factor index ff, as shownabove:

ff<1 Nonflowing1<ff<2 Verycohesive2<ff<4 Cohesive4<ff<10 Easyflowing10<ff Freeflowing

Anticipated uses of the Brookfield Powder Flow Tester:

Benchmarking-Measureflowpropertiesonallrawpowdersandblendstodetermineiftherearedifferencesintheirflowabilityandwhetherthesecorrespondwithplantexperience.

New materials - Test new ingredients/blends versus existing ingredients/blends to determine whetherthealternativematerialislikelytobeeasier,moredifficultornodifferenttohandle.This potential material handling cost can be factored into the purchasing decision.

Reverse engineering-Ifyouhaveplantexperiencewithpowdersthatfloweasilyorpoorlyonagivenprocessline,youcanusethePFTtodeterminetheflowpropertiesofeachpowderanddetermineovertimeaflowabilitywindowrequiredforflowonagivenline.

Design-Designthegeometry(convergingangleandoutletsize)ofnewhoppers/silosforreliableflow.

Alternative methods of displaying the flow function test results

Todemonstratepowderflowability,theflowfunctioncanbepresentedgraphically(asinFigureA-5)todescribebehavioroverthestressrangeofapproximately0.6kPato10kPa.Thisstressrange is representative of that experienced by the powder in small to intermediate sized silos. However,describingflowabilitywithafunctionmaycomplicatetheanalysisasitissometimesfoundthat theflowfunctionsof twodifferentmaterialscrossoveroneanother,sothat theirrelativerankingchangeswithstresslevels.Alternatively,flowabilityrankingsforspecificstresslevels can be determined by calculating the following parameters:


• Estimated Critical Arching diameter [m]: The minimum silo outlet size for reliable gravity dischargeinmass-flow,calculatedusingthearchingequationinFigureA-2b.Thestressvalueistheinterceptoftheflowfunctionwithanff=1.4line*.

• Estimated Critical ‘Rat-hole’ diameter in [m]: The minimum outlet diameter to prevent theformationofastable‘rat-hole’inacore-flowvessel.Theoutletdiameteriscalculatedusingtherat-holingequationinFigureA-2a.RefertothehelpfilesonRat-holediameterinthe Power Flow Pro software.

• Flow index: Thegradientofalinefromtheorigintothelastpointontheflowfunction(bydefault**),typicallyintherangeof0.1to1.0.Thisindexwillgiveacomparisonofmaterialsbehavior at intermediate compaction stresses greater than one meter depth of powder.

• Flow intercept:TheinterceptofthebestfitlinearflowfunctionwiththeunconfinedfailurestrengthaxisgivinganumberinkPa.Thisgivesanumberthatreflectsthepowdersflowabilityat compaction stresses typically less than 0.15m depth of powder.

* Thesearethedefaultflowfactorsettingsbuttheycanbeadjustedbytheuserwithina1.0to 10.0 range for silo design applications.

**Canbeusersettoanystresslevel.

Time consolidation test

TheTimeConsolidated Flow Function test compares the cohesive strength or hopper flowbehaviorofapowderthathasexperiencedabriefinterruptionofflow(afewseconds),tothesame powder after it has experienced static storage in the hopper for an extended period of time (ex.overnightorovertheweekend).

Note that the Friction Angles and Density Curve for a Time Consolidation test are based solely on the instantaneousflowdata andare therefore exactly the sameasdescribed in theFlowFunction section.

Note: A timeconsolidatedflowfunction testallows theuser to investigatewhether thematerial gains strength during long term storage.

Wall friction test

Thefrictionactingatthewall/powderinterfacehasasignificantinfluenceonthestressdistributionwithin processing vessels, silos and hoppers.

As wall friction increases, more of the powder weight is transferred down through the silo/ vessel/container walls, rather than compacting the bulk solid below. The lower the friction, the moretheself-weightistransmittedthroughthebulksolid.This‘Jansseneffect’isillustratedinFigure A-6, which demonstrates how the vertical pressures in the vertical section of a silo would vary if the wall friction were increased from zero to a large value of 40º. The presence of the wall friction has a negative feedback effect on the pressure increase with depth, so generally the stresses approach constant values at a depth of approximately 4 vessel diameters.


Dep

th o

f ves

sel i

n di

amet

ers

Z

Major Principal Consolidation Stress σ1

Hydrostatic pressure increase(pgh)

wall friction = 0 degwall friction = 20 degwall friction = 40 deg

0

0.5

1

1.5

2

2.5

3

3.5

4

Figure A-6: Stress distributions in vertical walled vessels Software can be used to estimate pressures in a container based on measurements of the bulk density ρ, wall friction ϕw, internal friction δj and container diameter D. The principal consolidation pressure σ1atdepthZisgivenbythefollowingequation.ThisequationisusedforRat-holecalculation.

σ1 = ρ · g · D 4 · λ · tanϕW

· (1 – e 4 · λ · tanϕw·Z)

D

We assume: λ = 0.4

Thisappliesonlytotheverticalsectionofthebinorsilo.“Kick-pressure”hasaneffectwhenthe powder gets into the hopper section.

The wall friction angle represents the angle to which a wall surface must be inclined as shown in Figure A-7 to cause powder to slip. The wall friction angle is typically in the range of 10 to 45 degrees.

The wall friction angle is also called the chute angle.

Powder slip

w

Figure A-7: Wall friction

02040


Outputs of the wall friction test

While the results of the wall friction test can be displayed graphically in the form of a wall friction locusasshowninFigureA-8a(representingthelimitingshearstressthepowdercansupportatawall),ortheformofawallfrictionanglefunctionasshowninFigureA-8b(representinghowthewallfrictionanglechangeswithreducingstress),oneofthefollowingfourflowindicesderivedfromthemaximumwallfrictionlocusareusuallyadequate.Thesewallfrictionpropertiesare:

• θc, θpThemaximummass-flowhopperhalfangle(measuredtothevertical)forconicalorplanar hoppers.

• ϕw The maximum wall friction angle to determine the minimum chute angle for gravity flow(seeFigureA-8b).

• GradThemaximumwallfrictionangledisplayedasacoefficient.• cw The wall cohesion shear stress in kPa that can be supported at the wall under zero

normalstress(seeFigureA-8a).Thisdeterminesthe‘stickiness’,i.e.whetherpowderislikely to stick to wall surface under close to zero stress. i.e. will powder build up on the walls of the chutes around discharge/transfer points.

Normal Stress σN

Wall Friction Locus (WFL)

Shea

r str

ess

8

τ

cw

Wal

l fric

tion

angl

e ϕ

w

Normal Stress σN

ϕw Maximum wall friction angle

90

0

Figure A-8a: Wall friction locus Figure A-8b: Wall friction function

An extended wall friction test allows the wall sample to be subject to large shear displacements (ontheorderof30meters)toestablishwhetherlongtermpowderbuilduponthewallwouldbe expected.

Bulk density test

It is the self-weight of the powder, its bulk density, that controls the stresses acting on the powder whenflowingorwhenstaticinprocessinglines/silosetc.Thebulkdensityismeasuredduringthecourseoftheflowfunctiontest(andisrequiredtocalculatethecriticaloutletdimensions)and the wall friction test, but it can also be measured in a separate single test for bulk density alone.

Compacted bulkdensity(ρcomp)


Incompressible material

Compressible material

Full bulk density(ρfill)

Major Principal Consolidation Stress σ1Bu

lk D

ensi

ty ρ

Figure A-9: Bulk density curve

Thebulkdensityiscommonlydisplayedasabulkdensitycurve(FigureA-9).Generallyafreeflowingmaterialwillbeincompressibleandonlyshowasmallincreaseindensitywithstress.Averycohesive,poorlyflowing,bulksolidbycomparisonwillshowalargeincreaseinbulkdensity with increasing stress.

ρfillThefillbulkdensity,whenthepowderisjustpouredintoacontainerρcomp The bulk density after the material is poured and compacted to high stress.

Summary

Tosummarize,theBrookfieldPowderFlowTesteroffersfourstandardtests,

1. Flow function test-Measuresinternalstrength,flowfunction,internalfrictionangleand bulk density - used for characterizing the flow strength and arching/ rat-holingpotential of powders.

2. Time consolidated flow function test–Sameasabovebutfollowingstaticstorageforauserdefinedtimeperiod.

3. Wall friction test - Measures friction between the powder and a given wall surface and thebulkdensity–usedforassessingmass-flowhopperhalfanglesandgravityflowchute angles.

4. Bulk density test–Measuresbulkdensitycurveofthepowder.

Note: Toundertakeafullsilodesignrequirestheusertorunandcombinetheresultsoftests 1, 2 and 3.


Appendix B: BCR Limestone Test Procedure for Calibration Check on Brookfield Powder Flow Tester

Background InformationBCR-116LimestonePowder(2500cc,3.2kgperjar)isthereferencematerialusedtoperformacalibrationcheck.ItiscertifiedbytheEuropeanCommission,JointResearchCentre,locatedinBelgium.ThepowderisavailableforpurchasefromBrookfield.9testscanbeperformedperjarwiththeStandardVolumeShearCell(263ccpertest),55testswiththeSmallVolumeShearCell(43ccpertest).Althoughbestpracticeistouseafreshsampleforeachtest,degradationofthelimestoneduringthetestisnotsignificant.Thereforethelimestonepowdercanthereforebereusedforadditionalcalibrationchecks.TheCertificateofAnalysiswhichcomeswiththeBCR-116 Limestone states that the material is valid for 5 years after purchase.

Sample PreparationCondition the limestone for 24 hours by spreading the powder out on the pan so in a thin layer no more than a centimeter deep. Use a metal scoop to break up any agglomerates. Maintain relative humidity between 40% and 60%RH, temperature between 22 and 28ºC. If it is not possible to achieve these test conditions, record the temperature and relative humidity for 8 hours prior to the test and report these values.

Test ProcedureFill the trough with powder using the metal scoop. Gently load the powder by allowing it to fall off the scoop into the annular ring. Rotate the scraping tool in a clockwise direction until the excess powder is removed. Reversing the direction of the scraping tool is acceptable to remove the excess powder. Make sure that the mound of powder in the annular ring is reasonably uniform all the way around. Fill the same way each time.

UsethesamelabtechniciantoruneachFlowFunctiontestonaspecificinstrument.Run3Flow Function tests at a minimum. Best practice is to run 7 Flow Function tests. Use the Vane Lid. Select theCustomFlowFunctionTest. Testmethod requires5consolidation stressesusing geometric spacing, 3 over consolidation stresses. Do not use a separate sample for each consolidation, do not repeat each measurement, and do not test at the point of tangency.

Record the temperature and the relative humidity for each test.

Data File ManagementThefilenameconventionillustratedbelowisrecommended.Identifythetestmaterialandsizeof shear cell under Product. Identify location of test, date of test, serial number of instrument, and initials of person doing the test under Batch:

Product:BCRLimestoneStandardVolumeShearCell Note:filelength<30charactersBatch:Brookfield9Jan2013SN789217RGM Note:filelength<30characters

Saveboththerawdatafileandthestressdatafileaftereachtest.UndertheAnalysisTabinthePowderFlowProsoftware,therawdatafileissavedwiththecheckboxnexttothediscicon


whichsavesthestressdatafileinADTGformat(AccessDatabase).ThelocationoftherawdatafileisfoundintheHELPmenuunderthe“About”Tab.

Problem ResolutionIfthereareanytechnicalissueswhenrunningthetest,savetheTechnicalSupportDisplayfile(communicationslogbetweenPFTandPCwhenusingPowderFlowProsoftware)whichisdisplayed on the Setup tab page.

Data AnalysisAveragethevaluesformajorprincipalconsolidationstressandunconfinedfailurestrengthfromalltests.Usethetableintheattacheddocument(BCRLimestoneCalibrationVerificationTable)to determine whether your PFT is in calibration.

Email the ADTG file for each test to Brookfield for our PFT records database, using [email protected].

Calibration Verification TablesWhenrunningtheflowfunctiontestdescribedabove,theaveragevaluesformajorprincipalconsolidatingstressandunconfinedfailurestrengthshouldfallbetweentheMINPASSandMAXPASS values in the tables below to verify calibration. Note that there are 5 levels of consolidating stress.Allstressandstrengthvalueslistedareinunitsofkilopascals(kPa).

IfthevaluesarebelowMINPASSoraboveMAXPASS,contactBrookfieldoryourlocaldealerfor service.

STANDARDVOLUMESHEARCELL(263cc)Consolidating Stress 1st 2nd 3rd 4th 5th

MIN PASS 0.566 1.110 2.209 4.426 8.950MAX PASS 0.658 1.278 2.487 4.842 9.540

Failure StrengthMIN PASS 0.471 0.737 1.285 2.090 3.316MAX PASS 0.613 0.999 1.602 2.591 4.087

SMALLVOLUMESHEARCELL(43cc)Consolidating Stress 1st 2nd 3rd 4th 5th

MIN PASS 1.420 2.969 6.004 12.11 24.66MAX PASS 1.684 3.227 6.372 12.63 25.65

Failure StrengthMIN PASS 0.782 1.305 2.142 3.220 5.318MAX PASS 1.238 1.965 3.066 4.999 8.015


Appendix C: Glossary

Angle of Wall Friction: Represents the friction between the sliding powder and the wall of the hopperorchuteattheonsetofflow.

Arching Dimension: Minimum hopper outlet size needed to insure that the powder will discharge in Mass Flow instead of forming a stable arch across the opening.

Axial Distance: Distance between the lid and the bottom of the trough, indicating the

depth of the powder.

Bin Diameter: Maximuminternaldiameterofthestoragevessel.Forsquareorrectanglevessels,theequivalentbindiametershouldbeused.

Bulk Density: The mass of the powder divided by its total volume.

Cohesion: A measure of the strength retained by a powder after if has been compacted to a given Consolidation Level.

Consolidation: The process of applying a Normal and a Shear stress to a bulk solid

to move the particles together, in order to observe any increases in its Cohesion, Bulk Density, etc.

Core-Flow: Afirst-inlast-outdischargepatternwherethepowderflowsfromthetopof the vessel through a vertical channel above the outlet. Powder that is near the walls of the vessel remains stagnant until the level descends to the point where that powder is at the top surface.

Critical Arch: The largest arch span that a given powder can support before collapsing under its self weight.

Critical Consolidation Stress: For Arching: The Major Principal Consolidating Stress acting on the powder in the

hopperatcriticalarchingdimensionduringmassflow.

For Rat-Hole: The Major Principal Consolidating Stress acting on the powder in the regionoftheoutletduetotheheadofpowderinacoreflowhopper.

Critical Density: The Bulk Density of the powder forming the Critical Arch or the

Critical Rathole. This is determined by taking the Bulk Density at the corresponding Critical Consolidation Stress.

Critical Internal Friction Angle: The Internal Friction Angle of the powder forming the Critical Arch or the Critical Rathole. This is determined by taking the Internal Friction Angle at the corresponding Critical Consolidation Stress.

Critical Rathole: The largest Rathole diameter a powder can support before collapsing in a Core Flow regime.

Critical Stress: TheUnconfinedFailureStrengthofthepowderformingtheCriticalArchor theCriticalRathole. This is determinedby taking theUnconfinedFailure Angle at the corresponding Critical Consolidation Stress.


Critical Wall Friction Angle: The Wall Friction Angle of the powder forming the Critical Arch or the Critical Rathole. This is determined by taking the Wall Friction Angle at the corresponding Critical Consolidation Stress.

Effective Angle of Internal Friction: Represents the friction between sliding layers of powder, defines theratio of the major and minor principal consolidation stresses during steadystateflow.

Failure Locus: The line of maximum Shear Stress that a powder can support before flowoccursundervariousOverconsolidatedNormalStresses. This isdependant on the Consolidation Level.

Fill Density: The Bulk Density of the powder in the trough before any stress is applied.

Flow Factor: (Arching)Ratioof theconsolidationstress inapowderduringSteadyState Flow to the stress required to set up a stable arch. This factordependsonboththeflowpropertiesofthepowderandtheshapeofthehopper.

Flow Function: Lineofapowder’sUnconfinedFailureStrengthversustheConsolidationstress that is applied to it.

Free-Flow: Thepowderflowsreliablythroughverysmalloutletdimensionsunder

gravity. Arching and Ratholing does not occur. This is indicated in hoppercalculationsas“FreeFlow”or“0.0”.

Geometeric Spacing: Seriesofvalueswhereeachvalueisequaltothepreviousvaluetimesaconstant factor. The factor is chosen to space the values over the entire range. In this type of series, there will be more values at the lower end of the range.

Hopper Half Angle: Maximumangleoftheconverginghopperwall(fromtheverticalaxis)neededtoensureMassFlow.Anglesgreater(shallower)thatthiswillproduce Core Flow.

Major Principal Consolidation Stress: The largest stress acting on the powder during Steady State Flow.

Mass-Flow: Afirstin-firstoutdischargepatternwherethepowderflowsatthevesselwalls and all the material is in motion.

No Flow: (Arching)ForthegivenFlowFactor,thepowderalwaysarches.Thisisindicatedinthehoppercalculationsas“NoFlow”or“-----”.

Normalized Flow Function: AversionoftheFlowFunctiongraph.The“normalized”flowfunctionprovides a means for comparing powder. The graph plots “potential arching diameter” against “major principal consolidation stress”.The mathematics involves dividing the density of the powder at each consilidation stress into the value for the unconfined failure strength.This approach analyzes the strength of the powder in the abstract, which meansthattheinfluenceofthehopperisnotincluded.


Normal Stress: The stress due to the Axial Load. It is stress applied perpendicular (normal)tothepowderbed.

Overconsolidation: After Consolidation, reducing the Normal Stress without shearing so that the Bulk Density is high relative to the new Normal Stress.

Rathole Diameter: Minimum outlet diameter of a Core Flow hopper needed to ensure that

thepowderwillflowinsteadofformingastableRathole.

Shear Stress: The stress due to the Torsional Load. It is the stress between parallel layersofpowder(FlowFunctionandTimeConsolidatedFlowFunctiontests)orbetweenalayerofpowderandthelid(WallFrictiontest).

Steady State Flow: Continuous powder flow where the Normal and Shear Stresses have

reached a constant level.

Time Consolidated Test: Compacts the powder at a given Consolidated Level for an extended periodoftime(hours,overnighttorepresentstaticstorageinahopper).

Torsional Distance: Distance that the trough has rotated from its starting position at the beginning of the test.

Unconfined Failure Strength: Thestress required tocauseapowder toflowatastress freesurface,after it has been compacted to a given Consolidation Level.

Wall Cohesion: A measure of the potential for the powder to stick to a wall surface. This depends on the Consolidation Level.

Wall Friction Test: The distance the powder travels across the wall surface before the Failure Locus is measured.


Appendix D: PFT Packing to Ship for Repair and Service

Note: All items must be packed as shown. If your packaging is missing, please contact Brookfield Engineering for replacement parts. Failure to do so could result in costly damage to the PFT.

If you saved the original packing instructions which came with the PFT, use them in accordance with the following instructions on page 63.

IfyouhaveorderednewpackagingmaterialsfromBrookfieldoranauthorizeddealer(PartNumber:PFT-REPACK),thefollowingitemshavebeenprovidedintheRepackKit:

PFTRSC500DW(accessorybox)(qty1): PFT-PACK1PFTHSC500DW(largeouterbox)(qty1): PFT-PACK2PFTTrayStitched(qty1): PFT-PACK31.7#PEFoamD/C’s(bottom)(qty1): PFT-PACK41.7#PEFoamD/C’s(top)(qty1): PFT-PACK5PFTShippingPallet(qty1): PFT-PALLETPolyBagforPFTShippingPack(qty1): PFT-BAGShippingFoam,CompressionPlate(qty1): PFT-104ShippingFoam(6-inchTrough)(qty1): PFT-101ShippingFoam(5-inchTrough)(qty1): PFT-1063x3x3.225StrappingProtectors(qty8): CTN-14Label,Box,Packaging&ShippingInfo(qty2): LBL11-PFT3Setof2,1in.x12ft.LashingStraps(qty2): PFT-116PFTPackingInstructionsforShipping(qty1): T11-1041VelcroStrapping,5/8wide(qty1): PFT-115

Bubble bags, rubber bands and packing newspaper will also be supplied in the Repack Kit.

Detailed instructions for packaging the PFT proceed on the following page. It is important to follow these instructions completely in order to prevent damage to the PFT during shipment.


1) Screw feet in all the way.

2) EnsurethattheVaneLid(PartNumberPFT-500for6”LidorPartNumberPFT-515for5”Lid)andTrough(PartNumberPFT-400for6”TroughorPartNumberPFT-405for5”Trough)areinstalledonthePFT.Thisisnecessaryinordertolockthe suspension system inside the instrument so that movement cannot take place during transport.


3) Raise the Vane Lid to its uppermost position by pressing the up arrow.

4) Placethecircularfoaminsert(PFT-101for6”TroughandPFT-106for5”Trough)into the Trough. Remove the Trough to accomplish this, if necessary, from the PFT. Install the Trough on the PFT.

5) Press the down arrow to lower the Vane Lid until it just makes contact with the foam insert. Then press and hold the down arrow for 2 seconds. This will adjust the position of the Vane Lid so that the foam is slightly compressed. Do not hold longer than 2 seconds because this will cause further compression of the foam insert, which is not desired.


6) Insertthehorseshoeshapefoamcollar(PFT-104)overtheLidandTrough.

NOTE: Flex the collar to an open position when installing around the bellows to ensure that the bellows do not deform.

7) Secure the access door for the bubble level by using plastic shrink wrap or tape that will not damage the paint. Secure the foam collar with plastic shrinkwrap or VelcroStrapping(PartNumberPFT-115),whichisalsosuppliedintheRepackKit.

Access Door for Bubble Level

Bellows


8) Insertthebottomfoampackagingpiece(PFT-PACK4)intothebottomoftheoutercartonpackagingkit(PFT-PACK3)andplaceontothepallet(PFT-PALLET),whichis also supplied in the Repack Kit.

NOTE: The marks indicating the front have two cut outs.

Cut Outs

Bottom Foam Packaging Piece

9) Placetheplasticbag(PFT-BAG)ontothebottomfoampackagingpieceandopenthe bag.

10) Gently insert the PFT into the bottom foam piece. Locate and lift the instrument, usingthehand-holdpositionsonthebottomandbackofthePFT.Thisrequirestwo people to lift the instrument.


11) Slide the plastic bag up over the PFT from the bottom to the top.

12) Secure the plastic bag at the top with a rubber band, which is supplied in the Repack Kit.

13) Placethetopfoampackagingpiece(PFT-PACK5)ontopofthePFT.

Top Foam Packaging Piece


14) Slidetheoutercartonbox(PFT-PACK2)overthePFTandinsertbetween the outer carton packaging kit and the bottom foam packaging piece.

Bottom Foam Packaging Piece

Outer Carton Packaging Kit


15) If the PFT will be sent back to you after repair or calibration, it is not necessary to return the accessory items other than the Vane Lid and Trough, which are already installed on the instrument. If the PFT is not being sent back to you, package all necessaryitemsinbubblebagsandplaceinaccessorycarton(PartNumberPFT-PACK1).

16) Close and tape up the accessory carton.

17) Placetheaccessorycarton(PFT-PACK1)ontopofthetopfoampackagingpiece.Ifyoudonothavetheaccessorycarton,pleasecontactBrookfieldforreplacementparts. If the accessory carton is not used, damage to the instrument may occur.


18) Close, tape and seal the outer carton box top.

19) Use2strapswiththestrappingprotectors(PartNumberCTN-14)tosecuretheoutercartonpackagingkit (PartNumberPFT-PACK3) inonedirection. Straptheoutercartontothepalletusing2morestrapswithstrappingprotectors(PartNumberCTN-14)intheotherdirection(seeFigureA).IfyouhavetheRepackKit,usethelashingstraps(PartNumberPFT-116)withthestrappingprotectors(PartNumberCTN-14)(seeFigureB).StrapsMUSTbesecuredtighttopreventany damage to the instrument while in transit.


Figure A Figure B

20) Apply labels which say “SHIP ONLY BY FREIGHT”. These labels are included in the Repack Kit (Part Number LBL11-PFT3). Place one label on the top of the shipping carton and one on the side, see figures below.

21) SHIP THE CARTON BY FREIGHT! Do not use a package carrier service. It is important that the carton remain in an upright vertical position during shipment in order to protect the instrument from damage.


Appendix E: Warranty Repair and Service

Brookfield Powder Flow Testers are guaranteed for one year from date of purchase against defects in materials and workmanship. The PFT must be returned to AMETEK Brookfield or the authorized dealer from whom it was purchased for warranty service. The PFT must be shipped via FREIGHT with all the original packaging provided with the instrument. If returning to Brookfield, please contact us for a return authorization number prior to shipping. Failure to do so will result in a longer repair time. Contact Brookfield if replacement parts are needed.

For repair or service in the United States return to:

AMETEK Brookfield11 Commerce Boulevard

Middleboro, MA 02346 U.S.A.Telephone: (508) 946-6200 Fax: (508) 923-5009

www.brookfieldengineering.com

For repair or service outside the United States, consult AMETEK Brookfield or the authorized dealer from whom you purchased the instrument.

For repair or service in the United Kingdom return to:

AMETEK (GB) LimitedBrookfield Technical Centre

Stadium WayHarlow, Essex CM19 5GX England

Telephone: (44) 1279/451774 FAX: (44) 1279/451775www.brookfield.co.uk

For repair or service in Germany return to:

AMETEK GmbHHauptstrasse 18

D-73547 Lorch, GermanyTelephone: (49) 7172/927100 FAX: (49) 7172/927105

www.brookfield-gmbh.de

For repair or service in China return to:

AMETEK Commercial Enterprise (Shanghai) Co., Ltd. Guangzhou BranchRoom 810, Dongbao Plaza

No. 767 East Dongfeng RoadGuangzhou, 510600 China

Telephone: (86) 20/3760-0995 Fax: (86) 20/3760-0548

On-site service at your facility is also available from Brookfield. Please contact our Service Department in the United States, United Kingdom, Germany or China for details.

Operating Instructions Manual No. M09-1200-F1016

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Transcript of Operating Instructions Manual No. M09-1200-F1016